Automatic container loader apparatus

ABSTRACT

AN AUTOMATIC CONTAINER LOADING APPARATUS FOR CONTINUOUSLY FEEDING CONTAINERS TO A FEEDER MEANS ON A CONTAINER FORMING AND FILLING MACHINE. THE LOADER APPARATUS COMPRISES A CONTAINER CONVEYOR MEANS INCORPORATING A MAGAZINE FEED SECTION FOR OPERATIVELY SUPPORTING A FIRST STACK OF CONTAINERS FOR FEEDING THE CONTAINERS TO SAID FEEDER MEANS, AND A CONTAINER RESERVE SECTION FOR OPERATIVELY SUPPORTING A RESERVE SECOND STACK OF CONTAINERS FOR AUTOMATIC TRANSFER TO SAID MAGAZINE FEED SECTION WHEN THE FIRST STACK IS REDUCED TO A PREDETERMINED NUMBER OF CONTAINERS, PUSHER MEANS OPERATIVELY MOUNTED ON SAID CONVEYOR MEANS FOR MAINTAINING A DECREASING PRESSURE ON SAID FIRST STACK OF CONTAINERS IN SAID MAGAZINE FEED SECTION FOR CONTINUOUSLY FEEDING THE CONTAINERS IN SAID FIRST STACK OF CONTAINERS TO SAID FEEDER MEANS, AND TRANSFER MEANS OPERATIVELY ENGAGEABLE WITH SAID SECOND STACK OF CONTAINERS IN SAID RESERVE SECTION FOR TRANSFERRING SAID SECOND STACK OF CONTAINERS FROM SAID RESERVE SECTION TO SAID MAGAZINE FEED SECTION FOR REPLENISHING SAID FIRST STACK OF CONTAINERS.

United States Patent {72] Inventors Robert C. Kellogg Wixom: Philip C. Martin, Walled Lake, Mich. [21] Appl. No. 815.045 [22] Filed Apr. 10,1969 [45] Patented June 28, 1971 [73] Assignee Ex-Cell-0 Corporation Detroit, Mich.

[5 1] AUTOMATIC CONTAINER LOADER APPARATUS 24 Claims, 17 Drawing Figs.

[52] U.S.Cl 221/11, 221/103 [51] 1nt.Cl t 1 G07fll/12 [50] Field of Search 214/8.5 (A);221/106,105,104,103,11,10,9,211; 271/5, 12, 69

[56] References Cited UNlTED STATES PATENTS 3,472,403 10/1969 Mueller et a1 221/11X 3,491,633 1/1970 White (221/103) Primary Examiner-Stanley H Tollberg Alt0rney-James H Bower ABSTRACT: An automatic container loading apparatus for continuously feeding containers to a feeder means on a container forming and filling machine. The loader apparatus comprises a container conveyor means incorporating a magazine feed section for operatively supporting a first stack of con tainers for feeding the containers to said feeder means, and a container reserve section for operatively supporting a reserve second stack of containers for automatic transfer to said magazine feed section when the first stack is reduced to a predetermined number of containers, pusher means operatively mounted on said conveyor means for maintaining a decreasing pressure on said first stack of containers in said magazine feed section for continuously feeding the containers in said first stack of containers to said feeder means, and transfer means operatively engageable with said second stack of containers in said reserve section for transferring said second stack of containers from said reserve section to said magazine feed section for replenishing said first stack of containers.

PATENTED JUN28 m SHEU 3 OF 9 I FIG. 3

INVENTORS OJIKT CT A1624 0 BY P/v/z/P c MflAT/A/ ATTORNEY PATENTED JUN28 IBYI SHEET H 0F 9 F'IG.4

l N V E N TO R 5 A oauwr a Kill 066 BY Pfl/z/P c MART/A FIG. 5

ATTORNEY PATENTED JUH28|9H 3587,9316

sum 7 or 9 F'IG. IO

INVENTORS ROBE/F7 (TA [1066 BYWMMGOM ATTORNEY AUTOMATIC CONTAINER LOADER APPARATUS SUMMARY OF THE INVENTION This invention relates generally to the container forming and filling art, and more particularly, to an automatic container loader apparatus for feeding collapsed containers to a continuous motion type forming and filling machine.

Container loader apparatuses have been provided heretofore for continuous motion type forming and filling machines. One example of these prior art container loader apparatuses is the magazine loader disclosed in U.S. Pat. No. 3,398,659. A disadvantage of the prior art container loader apparatuses is that they require constant operator attention to insure that the loader magazine is always loaded with containers. The operator is restricted to a constant job of manually loading containers into the magazine, and such action leads to operator fatigue. Another disadvantage of the prior art container loader apparatuses is that the containers are subject to being contacted by human hands during the process of stacking the containers in the loader apparatuses.

In view of the foregoing, it is an important object of the present invention to provide a novel and improved container loader apparatus which overcomes the aforementioned disadvantages of the prior art container loader apparatuses.

It is another object of the present invention to provide a container loader apparatus which may be manually operated or automatically operated.

It is still another object ofthe present invention to provide a container loader apparatus which is constructed and arranged to give an operator a maximum amount of free time so as to allow him to observe the forming and filling machines total operation and reduce operator fatigue.

It is still another object of the present invention to provide a container loader apparatus which has a large capacity, and which is efficient and fast in operation.

It is a further object of the present invention to provide a container loader apparatus which may be operated in a manner whereby human hands do not have to touch the collapsed containers being'fed to a container forming and filling machine.

It is a still further object of the present invention to provide an automatic container loading apparatus for continuously feeding containers to a feeder means on a container forming and filling machine. The loader apparatus comprises container conveyor means incorporating a magazine feed section for operatively supporting a first stack of containers for feeding the containers to said feeder means, and a container reserve secton for operatively supporting a reserve second stack of containers for automatic transfer to said magazine feed section when the first stack is reduced to a predetermined number of containers, pusher means operatively mounted on said conveyor means for maintaining a decreasing pressure on said first stack of containers in said magazine feed section for continuously feeding the containers in said first stack of containers to said feeder means, and transfer means operatively engageable with said second stack of containers in said reserve section for transferring said second stack of containers from said reserve section to said magazine feed section for replenishing said first stack ofcontainers.

It is another object of the present invention to provide an automatic container loading apparatus for continuously feeding containers to a feeder means on a container forming and filling machine and which includes an elongated conveyor plate for slidably supporting a first stack of collapsed containers at one end thereof and a second stack of collapsed containers at the other end thereof, a conveyor track operatively mounted adjacent said conveyor plate, a pusher means movably mounted on said conveyor track for maintaining a variable pushing pressure on said first stack of containers for feeding them to the container forming and filling machine, a transfer means movable mounted over said conveyor plate and operative to move said second stack of containers from said other end of the conveyor plate to said one end of the conveyor plate, and means for moving a third stack of containers from a loading position adjacent said conveyor plate onto said other end of said conveyor plate.

Other objects, features and advantages of this invention will be apparent from the following detailed description, appended claims, and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a front elevational view of a container loader apparatus made in accordance with the principles of the present invention and showing the container loader apparatus disposed adjacent a rotary container feeder apparatus.

FIG. 2 is a top plan view, with parts removed, of the container loader apparatus illustrated in FIG. 1.

FIG. 3 is an enlarged, rear end elevational view of the container loader structure illustrated in FIG. 1, taken along the line 3-3, and looking in the direction of the arrows.

FIG. 4 is a fragmentary perspective view of the container loader structure illustrated in FIG. 3, and taken in the direction of the arrow marked F" in FIG. 3.

FIG. 5 is a fragmentary, enlarged, elevational section view of the container loader structure illustrated in FIG. 1, taken along the line 5-5 thereof, and looking in the direction of the arrows.

FIG. 6 is a fragmentary, enlarged, plan view of the container loader structure illustrated in FIG. 2, taken along the line 6-6 thereof, and looking in the direction ofthe arrows.

FIG. '7 is an enlarged, front end elevational view of the container loader structure illustrated in FIG. 1, taken along the line 7-7 thereof, and looking in the direction of the arrows.

FIG. 8 is an enlarged, elevational view, partly in section, of the container loader structure illustrated in FIG. 1, taken along the line 8-8 thereof, and looking in the direction of the arrows.

FIG. 9 is a fragmentary, enlarged, elevational section view of the container loader structure illustrated in FIG. 4, taken along the line 9-9 thereof, and looking in the direction 'of the arrows.

FIG. 10 is an enlarged, elevational section view with parts removed, of the container loader structure illustrated in FIG. 1, taken along the line 10-10 thereof, and looking in the direction of the arrows.

FIG. 11 is an enlarged, elevational section view of the container loader structure illustrated in FIG. 1, taken along the line 11-11 thereof, and looking in the direction of the arrows.

FIG. 12 is a fragmentary, enlarged, horizontal section view of the container loader structure illustrated in FIG. 8, taken along the line 12-12 thereof, and looking in the direction of the arrows.

FIG. 13 is a fragmentary, enlarged, elevational view of the container loader structure illustrated in FIG. 2, taken along the line 13-13 thereof, and looking in the direction of the arrows.

FIG. 14 is a top plan view of the container loader structure illustrated in FIG. 13, taken along the line 14-14 thereof, and looking in the direction of the arrows.

FIG. 15 is a fragmentary, elevational section view of the container loader structure illustrated in FIG. 13, taken along the line 15-15 thereof, and looking in the direction of the arrows.

FIG 16 is an illustrative electric control circuit for the container loader apparatus of the present invention.

FIG. 17 is an illustrative fiuid control circuit for use in operating the container loader apparatus of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT The automatic container loader apparatus of the present invention is adapted to feed collapsed containers or cartons to a feeder means associated with a container forming and filling machine, and in particular, to a rotary or turret type feeder apparatus and a continuous motion type forming and filling machine. The loader apparatus of the present invention is adapted to convey various types of containers to a feeder apparatus, such as the various types of containers shown in U.S. Pat. Nos. 3,120,333, 3,185,376 and 3,185,376. U.S. Pat. Nos. 3,392,458 and 3,398,659 illustrate continuous motion container forming and filling machines of the type that may be operatively associated with the loader apparatus of the present invention. A rotary feeder apparatus of the type which may be operatively associated with the loader apparatus of the present invention is disclosed in U.S. Pat. No. 2,936,681.

GENERAL MACHINE DESCRIPTION Referring now to the drawings, and in particular to FIGS. 1 and 2, the numeral generally indicates an automatic container loader apparatus made in accordance with the principles of the present invention. In FIG. 1, the numeral 11 generally indicates a fragmentary portion of a continuous motion container forming and filling machine of the type which would be supplied with containers by the loading apparatus 10. The fragmentary structure indicated generally by the numeral 12 in FIG. 1, designates a rotary feeder means of the type which would be fed by the loading apparatus 10.

As shown in FIGS. 1 and 2, the container loader apparatus of the present invention includes a container conveyor means, generally indicated by the numeral 13, which includes a forwardly disposed magazine feed section indicated by the numeral 14 and a rearwardly disposed reserve section indicated by the numeral 15. The magazine feed section 14 operatively supports a first stack of containers for feeding the containers to the rotary feeder means 12. The reserve section 15 operatively supports a reserve second stack of containers for automatic transfer to the magazine feed section 14 when the first stack of containers is reduced to a predetermined number of containers. The numeral 16 generally designates a pressure means which is operatively mounted on the conveyor means 10 for maintaining a decreasing pressure on the first stack of containers in the magazine section 14 for continuously feeding the containers in the first stack of containers to the rotary feed means 12. The loader apparatus 10 of the present invention further includes a transfer means generally indicated by the numeral 17 which is operatively engageable with a second stack of containers in the reserve section 15 for transferring the second stack of containers from the reserve section 15 to the magazine feed section 14 for replenishing the first stack of containers. As shown in FIG. 3, the loader apparatus 10 includes a loading means generally indicated by the numeral 18 for loading containers into the conveyor means reserve section 15 for renewing the first stack ofcontainers.

CONTAINER CONVEYOR MEANS As shown in FIG. 7, the container conveyor means 13 includes a pair of longitudinally disposed, laterally spaced apart frame rails 21 and 22 which are supported at their front ends of the transverse member 23 of a frame front base member generally indicated by the numeral 24. The frame rails 21 and 22 are secured by the machine screws 25 to the integral vertical legs 26 and 27 of the base member 24. Base member 24 is secured to the forming and filling machine 11 by any suitable means, as by machine screws 28.

As shown in FIGS. 1 and 5, the frame rails 21 and 22 are supported at a second position of the forming and filling machine 11 by an intermediate base member generally indicated by the numeral 29. As shown in FIG. 5, the rails 21,

and 22 are secured to the base member 29 by any suitable means, as by the machine screws 30. The numeral 31 in FIGS. 1, 3 and 6 designates a base plate on which the rails 21 and 22 are supported adjacent the rear end ofthe conveyor means 13. The rails 21 and 22 are connected to the base plate 31 by suitable screws in the same manner as described hereinbefore for the base members 24 and 29. As shown in FIG. 3, the base plate 31 is integrally connected to a boss 32 that has threadably mounted in its lower end an upper support leg 33.

A lower, ground engaging leg 35 is adjustably mounted in the lower end of the upper leg 33 and it is adapted to be locked in an adjusted position by a suitable lock nut as 34.

As shown in FIGS. 7 and 8, the conveyor means 13 further includes a pair of guide track members generally indicated by the numerals 38 and 39. The track members 38 and 39 are secured to the base legs 26 and 27, respectively, by suitable machine screws 40 in a position spaced above the rails 21 and 22. The guide tracks 38 and 39 are supported at one point by a pair of vertical posts 41 and 44, as shown in FIG. 10. The post 41 is secured by suitable machine screws 42 to the outer side of the rail 21. The track member 38 is secured by machine screws 43 to the post 41. As shownin FIG. 1, the post 41 is located adjacent the front end of the conveyor reserve section 15. As shown in FIG. 10, the post 44 is located in a position opposite to the post 41 and is secured to the rail 22 by the machine screws 45. The track member 39 is secured to the post 44 by the machine screw 46. As shown in FIGS. 1 and 3, the conveyor rails 21 and 2 are supported at their rear end by the frame rear vertical end plate 47. The rails 21 and 22 are secured to the plate 47 by suitable machine screws 48. The track members 38 and 39 are secured to the end plate 47 by the screws 49. As shown in FIG. 5, each of the track members 38 and 39 comprises an upper guide bar 52, a spacer bar 53, and a lower track plate 54. The bars 52 and 53, and the plate 54 are secured together by any suitable means, as by a plurality of machine screws 55.

As illustrated in FIG. 8, the container conveyor means 13 further includes a longitudinally disposed conveyor plate 56 which is mounted on the track members 38 and 39 and secured thereto at its forward end by any suitable means as by a plurality of machine screws 57. As shown in FIG. 10, the rear end of the plate 56 is secured in place by machine screws 58 which extend vertically through the plate 56 into the track members 38 and 39. As shown in FIG. 3, the plate 56 is provided at the rear end thereof, inthe reserve section 15, with an integral vertically disposed plate 59 along its rear side to support one side of the second stack of containers 60 which is inserted into the reserve section 15 by the loader means 18.

The container conveyor means 13 includes a pair oflongitudinally disposed round guide rails or bars 61 and 62 which extend throughout the length of the magazine feed section 14. A second set of longitudinally disposed round guide rails or bars 63 and 64 are also mounted above the guide rails 61 and 62 in vertically aligned positions.

As shown in FIG. 7, a first clamp plate 65 is adjustably mounted by a pair of machine screws 66 on the lower end of a vertically disposed support bar 67 that is secured by a suitable machine screws 69 on a horizontal support arm 68 formed on the upper end of the base vertical leg 26. A second adjustable clamp plate 70 is also secured by a pair of machine screws 71 to the vertical support bar 67 adjacent the upper end thereof. A second vertical support bar 78 is secured to a second horizontal support arm 79 formed on the base leg 27, by suitable machine screws 80. Adjustably mounted on the lower end of the support bar 78 is a horizontally disposed clamp plate 76 that is secured thereto by a pair of machine screws 77. A second horizontally disposed clamp plate 81 is adjustably mounted on the support bar 78 at a pointadjacent the top thereof by a pair of machine screws 82.

As shown in FIG. 7, a vertically disposed retainer bar 83'is secured between the clamp plates 65 and 70 by a pair of machine screws 84 and 85 which are also adapted to be threaded into the front ends of the guide rails 63 and 61, respectively, for supporting these guide rails at the forward ends thereof. The clamp plates 76 and 81 each have mounted on their inner ends thereofa retainer disc 86. The discs 86 are each secured to their respective plates by the machine screws 87 and 89 which are also threaded into the forward ends of the guide rails 64 and 62, respectively, for securing the front ends of these rails in place. The bolt and nut assemblies 88 further assist in clamping the disc screws 87 and 89 in place on the plates 81 and 76, respectively.

As shown in FIG. I, the rear end of the guide rail 61 is supported in a suitable recess in the vertical post 41. As shown in FIG. 5, the rear end of the guide rail 62 is also supported in a similar manner in the vertical post 44. As shown in FIGS. 1 and 2, the upper front guide rail 63 terminates at a point indicated by the numeral 72, which is at a position adjacent the forward end of the conveyor means 13. On the other hand, the rear upper guide rail 64extends for the full length of the conveyor means 13 and it is supported at its rear end in a suitable hole formed through the conveyor frame rear end plate 47.

As viewed in FIG. 7, it will be seen that the first stack of containers 60 in the magazine feed section 14 are retained in the magazine section at the forward end thereof, by the vertically disposed plate 83 which is moved into an operative position by adjusting the plates 65 and 70 so that the inner edge of the plate 83 slightly overlaps one edge of the front container in the magazine section 14. The other edge ofthe front container in the magazine section 14 is retained by the discs 86 which 7 are also adjusted for operative overlapping engagement with said front container by adjusting the plates 76 and 81, as required. The plate 83 and the discs 86 provide a retaining force on the first stack of containers 60 in the magazine section 14 but yet permit thecontainers to be withdrawn from the magazine section 14 by the feeder apparatus 12.

As shown in FIGS, 1 and 7, the conveyor means 13 is provided with a hook member adapted to engage the upper edge of the front container in the magazine section 14 so as to assist in opening the front container as it is withdrawn by the feeder means 12. The last mentioned hook member comprises a vertical rod portion 90 which is integrally connected at its upper end to a transverse rod portion 91. The rod portion 91 is integrally connected at its outer end to the upper end of a second rod or vertical leg 92 that is adjustably mounted in a hole 93 formed in the upper end of the support bar 67 and secured in an adjusted position by a lock screw 94.

As shown in FIGS. 2 and 7, a vertical dirt shield 95 is mounted on the rear side of the front end of the magazine section 14. The front end of the shield 95 is suitably secured by the bracket 96 to the vertical support bar 78. As shown in FIG. 5, the rear end of the shield 95 has suitably secured thereto, as by welding, the brackets 97 and 102 which are attached by the screws 98 and 103 to the horizOntal support plate 99 and base member 29, respectively. The support plate 99 is secured by a machine screw 100 to the vertical leg 101 of the base member 29.

The conveyor means 13 may also be covered by a dust shield, as 107, as shown in FIGS. 2, 3, 7 and 10. As shown in FIG. 7, the forward end of the shield 107 has fixed thereto as by welding, a pair of mounting brackets 108 and 109 which are secured at their lower ends by any suitable means as by welding, to the support bars 67 and 78, respectively. As shown in FIG. 10, the shield 107 is supported atan intermediate point by the bracket 110 which is suitably secured thereto, as by welding. The bracket 110 is secured by suitable bolts to the post 41. The rear end of the shield 107 is secured, as shown in FIG. 3, to the conveyor rear end plate 47 by suitable support bars 111 and 112.

MAGAZINE PRESSURE MEANS As shown in FIGS. 1 and 8, the magazine pressure means 16 is provided with a pair of spring biased pusher means, generally indicated by the numerals 115 and 116, on the front side of the conveyor means 13, and with a second pair of vertically disposed spring biased pusher means 118 and 119 on the rear side of the conveyor means 13. The pusher finger means 115 and 116 are mounted on a front pusher plate 117. The pusher finger means 118 and 119 are mounted on a rear pusher plate 120. The pusher finger means 115, 116, I18 and 119 are each formed in the same manner, and accordingly, only one of them has been shown in detail in FIG. 12.

The pusher finger means 115 is shown in FIG. 12 as including a pusher finger 121 which has its front end 122 in pushing engagement with the last container in the front stack of containers 60 in the magazine section 14. The pusher finger 121 is normally biased sidewardly inward over the conveyor means 13. The pusher finger 121 is pivotally mounted at its rear end on the vertical pivot pin 123 which is carried in the front end of a yoke member or carrier plate 125. The pin 123 extends through a horizontal slot 124 formed through the yoke member 125. The finger 121 is pivotally mounted in the slot 124 on the pin 123. The carrier plate 125 is adjustably secured in place on the pusher plate 117 by a pair of machine screws 126 which extend through a horizontal slot 127 formed in the plate 117. A spacer plate 128 is mounted between the carrier plate 125 and the plate 117. A spring 129 is mounted around the pivot pin 123 and it has one end abutting the spacer-plate 128 and the other end abutting the finger 121 in a slot 130 formed through the finger 121. It will be seen that the spring 129 normally biases the pusher finger 121 inwardly yet permits a replenishment stack of containers 60 to be pushed thereby during a magazine section replenishing operation.

As shown in FIG. 8, the pusher plates 117 and 120 are carried on a pusher carriage generally indicated by the numeral 133. The pusher carriage 133 includes the horizontal frame member 134 which is rollably supported by a first pair of rollers 135 mounted in the track member 38 and a second pair of rollers 136 rollably mounted in the track member 39. Integrally formed on the front side of the carriage frame member 134 is a vertical frame leg 137 to which is secured the pusher plate 117 by suitable machine screws 138. A second vertical frame leg 139 is integrally formed on the rear end of the carriage frame member 134 and has secured thereto, by machine screws 140, the pusher plate 120. The pusher carriage 133 is further provided with a pair of guide rollers 141 on the front side thereof which are in rolling engagement with the inner side of the rail 21, and a second pair of guide rails 142 which are in rolling engagement with the inner side of the rail 22.

As shown in FIGS. 1 and 8, an upwardly extended cam 143 is integrally formed on the upper end of the pusher plate 120 for coaction with a cam follower on the transfer means 17, as more fully described hereinafter. As shown in FIG. 8 the pusher carriage 133 is provided with a pair of bumper blocks 144 and 145. The forward ends thereof are adapted to engage the vertical legs 26, and 27, respectively, of the base frame 24 when the carriage 133 is moved to its extreme forward end position.

As shown in FIG. 1, the pusher carriage 133 is adapted to be moved forwardly and backwardly by a suitable rotary fluid motor generally indicated by the numeral 148. Any suitable rotary fluid motor may be employed. For example, a suitable air operated motor of this type is available on the market from the Graham Engineering Company, Inc. of Palo Alto, California, under Model No. 2.5, and it is sold under the trademark ROTA-CYL." The fluid motor 148 is suitably affixed at its rear end to the lower side of the conveyor 13 by the bracket 149, and its front end by a similar bracket 150. As shown in FIGS. 1 and 10, the fluid motor 148 is provided with an output shaft 151 to which is fixed the drive sprocket 152. The sprocket 152 drives a continuous chain 153 which is extended upwardly around an idler sprocket 154 and thence forwardly as shown in FIG. 2, to the chain attachment means 155 that is carried on the underside of the carriage 133. The chain attachment means 155 is shown in FIG. 8. The chain 153 extends forwardly from the attachment means 155, as shown in FIG. 2, around the sprocket 156. The chain then extends rearwardly around the idler sprocket 157 (FIG. 1) and back to the sprocket 152. As shown in FIG. 10, the sprocket 154 is rotatably mounted in a suitable manner on the shaft 158 that is operatively supported by a post 159 on a transverse support bracket 160. The transverse support bracket 160 is secured by suitable machine screws 161 to the underside of the conveyor rails 21 and 22. As shown in FIG. 11, the sprocket 157 is carried on a suitable shaft 163 which has its ends supported in the rails 21 and 22 and which is spaced from these rails by a pair of spacer sleeves 162. As shown in FIG. 7, the sprocket 156 is mounted in a rotatable manner on the upper end ofa sprocket support post 166 which is integrally mounted on a support base member 167 that is secured to the base member portion 23 by suitable machine screws 168.

As shown in FIGS. 1 and 10, the fluid motor output shaft 151 also carries a second drive sprocket 169 around which is mounted a drive chain 170. The chain 170 is also mounted around a driven sprocket 171 which drives an air pressure regulator, generally indicated by the numeral 172 in FIGS. 1 and 11. As best seen in FIG. 11, the air pressure regulator 172 is carried on a bracket 173 that is secured by a machine screw 174 to the conveyor rail 21. The pressure regulator 172 functions to mechanically vary the pressure of the air conveyed to the fluid cylinder 148, as more fully described hereinafter.

As shown in FIG. 8, the pusher carriage 133 is provided with a limit switch operator 175 that is carried on the bumper 145.

CONTAINER TRANSFER MEANS The container transfer means 17 comprises a U-shaped carrier bracket illustrated in FIGS. 1, 3 and 6 which comprises a bight portion 178 and two integral leg portions 179 and 181. The carrier bracket leg portion 179 is slidably mounted on the horizontal, longitudinally extended carrier bar 180. The carrier bracket leg portion 181 is rollably supported on the conveyor plate 56 by a suitable roller 182, as shown in FIG. 3. As shown in FIGS. 1 and 3, the carrier bracket leg 181 carries pusher plate 183 which is secured thereto by the bolts 184 and 185. A limit switch operator 186 is also carried by the carrier bracket leg 181. As shown in FIGS. 3 and 6, the rear end of the carrier bar 180 is supported in a suitable hole in the conveyor rear end plate 47. As shown in FIG. 7, the front end of the carrier bar 180 is supported in the support bar 78. The car rier bar 180 is supported in an intermediate position, as shown in FIGS. 6 and 8, by a spacer member 187 which is secured to the carrier bar 180 by any suitable means. The spacer member 187 is suitably attached to a horizontal support plate 188 which is welded to the upper end of a vertical support plate 189 that is suitably secured to the vertical post 44.

As shown in FIGS. 1 and 6, the transfer means carrier includes a vertical bracket 190 which is slidably mounted on the carrier bar 180 in a position spaced apart forwardly from the UO-shaped carrier bracket leg 179 by a tubular bar 191 which is secured at its front end to the bracket 190 by the machine screws 192 and to the bracket leg 179 by the machine screws 193.

As shown in FIGS. 1, 10, 13 and 14, the carrier bracket 190 pivotally supports a container retainer plate 194 which is disposed transversely across the conveyor means 13 and adapted to engage the front container of the stack of containers 60 disposed in the reserve section 15. As best seen in FIG. 13, the retainer plate 194 is vertically disposed and is integrally connected at its upper end to a horizontal plate 195 that is secured by machine screws 196 to the plate extension 197 of the plate 198. As shown in FIGS. 13 and 14, the plate 198 is attached by the machine screws 199 to the forward end of a pivot bar 200. The bar 200 is pivoted at an intermediate point on a pivot shaft 201 between the yoke arms 202 that are formed on the upper end of the carrier bracket 190. As shown in FIG. 14, the pivot shaft 201 is pivotally mounted in the bushings 203 secured in the yoke arms 202. As shown in FIG. 13, the pivot bar 200 is restrained in its clockwise pivotal movement by a horizontal stop arm 204 which is integrally attached to a vertical arm 205 that is secured by the screws 206 to the vertical bracket 190.

As show in FIGS. 13 and 14, the bar 200 carries a lifter cam follower 209 which comprises a suitable roller that is rotatably attached by the machine screw 210 to the vertical leg 211 ofa cam mounting bracket that includes a horizontal leg that is attached by the screws 213 to the plate 198. The cam follower 209 is adapted to engage the fixed cam 143 on the carriage plate when the transfer means 17 is moved forwardly, as described in detail hereinafter, so as to lift the retainer plate 194 upwardly and free it from engagement with the containers in the stack of containers being moved into the magazine section 14.

As shown in FIGS. 13 and 14, the rear end of the pivot bar 200 is provided with a cutout or notched portion 214 which is adapted to be engaged by a pawl finger 215 on a pivotally mounted pawl 216. The bar 200 is limited in its counterclockwise pivotal movement about the shaft 201 by the stop member 217 which is carried on the screw 218 that is threadably mounted on the tubular carrier bar 191. The numeral 219 in FIG. 13 indicates the broken line position of the pivot bar 200 when it is moved or lifted upwardly to move the retainer plate 194 clear of a stack of containers being transferred into the magazine section 14.

The pawl 216 is pivotally mounted on the shaft 220 which is rotatably mounted in a pair of suitable bearings 222 between the two yoke arms 223, as shown in FIG. !14. The yoke arms 223 are fixedly secured by the machine screws 224 to the tubular carrier bar 191. A pair of spacer plates 225 are mounted between the bar 191 and the yoke arms 223. As best seen in FIG. 13, a pawl spring 226 has one end operatively mounted in a hole in the rear side of the pawl 216, and the other end of the spring is mounted in a suitable hole in a spring support bar 227 that is fixed to the rear ends of the yoke arms 223. The spring 226 normally biases the pawl 216 into a holding engagement with the bar 200 to hole it in the lifted position 219. The last described structure thus functions as a holding means for holding the bar 200 in its raised position 219.

As shown in FIGS. 13 and 15, a release lever 228 is attached by a screw 229 to the pawl pivot shaft 220. The lever 228 extends downwardly and is adapted to engage an abutment member 237 which is an adjustable stop screw. The adjustable stop screw 237 is threadably mounted in the upper end of a bracket 238 (FIG. 6) and is secured by the screws 239 to the conveyor rail 22. As shown in FIG. 13, the screw 237 is secured in an adjusted position by a lock nut 232. It will be seen that when the transfer means 17 retracts to the position shown in FIG. 6, the lever 228 will be rotated clockwise, as viewed in FIG. 6, to unlatch and release the pawl finger 215 from the notch 214 on the bar 200 and permit the retainer plate 194 to drop down to its normal container retaining position.

The transfer means 17 is adapted to be moved forwardly and backwardly over the conveyor means 13 by a rotary fluid motor which is generally indicated by the numeral 240 (FIG. 6), and which is constructed and operated in the same manner as the previously described motor 148. The fluid motor 240 is secured by screws 241 at its front end to the first vertical leg 242 of an angle bracket which has a second vertical leg 243 secured by the screws 244 to the conveyor rail 22. The front end of the fluid motor 240 is attached by a similar mounting bracket to the rail 22. The fluid motor 240 is provided with an output shaft 245 on which is mounted a drive sprocket 246 that drives a continuous chain 247. The chain 247 extends upwardly into a chain clamp means 249 that is carried on the lower end ofa carrier bracket 248 The bracket 248 is attached by the screws 250 to the carrier bar 191. The chain 247 also passes over an idler sprocket 251 which is suitably supported on the conveyor means 13. As shown in FIGS. 1 and 5, the chain 247 is extended forwardly and is trained around the idler sprocket 253 which is rotatably mounted on a support bar 254 that is fixed by screws 255 to the base leg 101. As shown in FIG. 5, the carrier bracket carries a limit switch operator 256 on the lower end thereof.

The numeral 257 in FIGS. 1 and 8 indicates a stop member which is engaged by the carrier bracket 190 when it is moved to its advanced broken-line position 258 shown in FIG. 1. The numeral 259 in FIG. I shows the broken-line retracted position ofthe pusher means 16 CONTAINER LOADING MEANS As shown in FIGS. 3 and 4, the container loading means 18 includes a loading tray comprising a bottom wall 265 and a front wall 266. Attached to the right end of the loading tray, as viewed in FIG. 4, is a right end wall 267. The loading tray bottom wall 265 is provided with a cutout portion 268 on the left end thereof. The loading tray is provided with a support frame that includes a pair of spaced apart transverse frame bars 269 and 270 which are interconnected by a frame bar 272. A longitudinal frame bar 271 is disposed along the entire rear end of the loading tray. The loading tray frame further includes a short longitudinal frame bar 273 that extends to the left, out wardly from the transverse frame bar 269, as viewed in FIG. 4. The aforementioned frame bars are secured to the bottom wall 265 by any suitable means, as by welding.

The loading tray is provided with a handle means that includes a first handle bracket 274 which is secured by the screws 276 to the frame bar 269. A second handle bracket 275 is secured by the screws 277 to the frame,bar 270. A handle bar 278 is operatively mounted in suitable holes formed in the brackets 274 and 275. The handle brackets 274 and 275 are provided with suitable brace bars 279 and 280 along the outer side of the front wall 266.

As shown in FIG. 4, the loading tray is pivotally mounted on a hinge shaft 285 by the hinge members 281 and 282. The hinge members 281 and 282 are secured by the screws 283 and 284, respectively, to the underside of the frame bars 269 and 270. The hinge shaft 285 is carried by the mounting brackets 286, 287 and 288 which are suitably secured to the conveyor rail 21 and track means 38, by any suitable means. The hinge shaft 285 is secured in place in the mounting brackets by suitable lock screws as 289.

It will be seen in FIG. 4, that the loading tray is adapted to be slid from the position shown in FIG. 4, to the right, away from an abutment plate 290. This lateral movement is provided to permit a box of collapsed containers to be emptied into the loading tray and the tray then slid to the left to compress the containers against the abutment plate 290 before the tray is tipped or swung upwardly to load the containers in the reserve section 15. As shown in FIG. 3, the abutment plate 290 is attached by the screws 291 to the end plate 47. The lower end 292 of the abutment plate 290 is attached by the screws 294 to a brace plate 293 that has its inner end secured by the screws 295 to the end plate 47.

As shown in FIGS. 4 and 9, the loading tray is provided with a safety means to prevent the tray from being swung upwardly to load containers into the reserve section if it is not in the extreme left loading position of FIG. 4 A safety lock dog 298 has one end fixedly secured by any suitable means to the underside of the tray frame member 271. The lock dog 298 has its other end rotatably mounted on the hinge shaft 285 and it carries a shoulder 299 which is adapted to abut the upper end of a safety lock block 300 to prevent unintentional tipping up of the loading tray when the loading tray is in a position moved the right, as viewed in FIG. 4. The block 300 is attached by the screws 301 to the track member 38.

It will be seen that when the loading tray is moved to the tray unloading position of FIG. 4, the dog 299 will be free to rotate past the block 300 to permit the tray to be rotated upwardly in a counterclockwise direction as viewed in FIG. 3. As shown in FIG. 3, the loading tray is adapted to rest on a pad 296 that is carried on asupport arm 297 which is attached to the boss 32,

CONTROL MEANS An illustrative electric control circuit for use with the container loader apparatus of the present invention is shown in FIG. 16. FIG. 17 illustrates a fluid control circuit for use in operating the container loader apparatus. The control switches for these circuits may be mounted in a suitable control panel, as 302, on the front side of the conveyor means 13, as illustrated in FIG. 11.

The transfer means 17 may also be termed a transport means, and the magazine section pressure means 16 may also be termed a pusher means.

As shown in FIG. 17, the rotary fluid motors 148 and 240 are supplied with pressurized air form a suitable source through the conduit 303 and an adjustable pressure regulator 304. Air under an adjusted constant or steady pressure is supplied from the regulator 304 to one end of the pusher means motor 148 through the conduit 305, the flow control valve 306, conduit 307, flow regulator 308, and conduit 309. The steady pressure supplied to the motor 148 is to effect the retracting movement of the pusher means 16. Air under steady pressure is supplied from the regulator 304 to the other end of the pusher means motor 148 through the conduit316, mechanical pressure regulator means 172, conduit 314, the flow control valve 313, conduit 312, flow regulator 311 and conduit 310.

Both ends of the transfer means fluid motor 240 is supplied with air under constant or steady pressure from the regulator 304 through the conduit 316 and the four-way control valve 317. The valve 317 is connected to one end of the fluid motor 240 through the conduit 318, flow regulator 319 and conduit 320, and to the other end of the fluid motor 240 through the conduit 323, flow regulator 322 and conduit 321. The sole noids 10, 11 and 12 operate the valves 306, 313 and 317, respectively.

As shown in FIG. 16, the pusher motor control solenoids l0 and 11 are adapted to be energized from a suitable source of electric power through the leads 324 and junctions 325 and 326. The transfer or transport motor solenoid 12 is connected to the leads 324 through the junctions 326 and 327. The pusher control limit switches 13 L.S. and 12 L.S. are connected to the leads 324 through the junctions 328 329, 330 and 33], leads 332 and 335, and junctions 333, 334 and 336. The transport control limit switches 14 L.S. and 15 L.S. are connected to the leads 324 through the junctions 328, 329, 338 and 337.

OPERATION The loader apparatus of the present invention may be controlled manually or automatically with the circuit illustrated in FIG. 16. When the loader apparatus is to be initially loaded for a production run the magazine" switch is turned to the manual position and the pusher means 16 and transfer or transport means 17 may be manually and separately controlled by the pusher" and transport switches. After the magazine section 14 has been loaded with containers 60, the operator turns the magazine switch to automatic," loads a stack of containers 60 into the reserve section 15 and then presses the transport loaded pushbutton switch. The closing ofthe transport loaded" switch energizes the time delay relay 6TR which informs the pusher means 16 that the transport or transfer means 17 is loaded. When the pusher means 16 moves forward a distance sufficient to make room in the magazine section 14 for a replenishment stack of containers 60, the limit switch operator on the carriage 133 contacts the normally open 12 L.S. limit switch and closes it to energize time delay relay STR which energizes solenoid 12 to send the transfer means 17 forwardly and transfer another stack of containers into the reserve section 14.

When the transfer means 17 has advanced in the magazine section 14, the limit switch operator 256 on the transfer carrier bracket 190 engages limit switch 14 L.S. to energize time delay relay 7TR which energizes solenoids 10 and 11 to actuate the pusher means 16 to retract to its fully retracted position 259 (FIG. 1). This action makes pusher means 16 move rearwardly past the new stack of containers being loaded into the magazine section 14. When the pusher means 16 gets back to its fully retracted position 259 the limit switch operator 175 engages normally closed limit 13 L.S. and opens it to knock out time delay STR and deenergize the pusher solenoids l0 and 11 which operate the flow control valves 306 and 313 to send the pusher means 16 forwardly. The transfer means 17 is held in its forward position to allow enough time for it and the pusher means 16 to advance together forwardly for a short length of time and permit the pusher finger means 115, 116, 118 and 119 to engage the last container of the new stack in the reserve section 14. The transfer means 17 then retracts until the limit switch operator 186 engages the normally closed limit switch 15 L8. to open the same and deenergize the time-delay relay 7TR.

It will be understood that when the pusher means 16 makes its retracting movement to position 259, the cam roller 209 engages the sloping cam 143 on the pusher plate 120 to elevate and lift the retainer plate 194 to an inoperative position while the transfer means 17 moves forward to load a stack of containers into the reserve section. When the pivot bar 200 is raised to the lifted position 219 (P10. 13), the pawl 216 is biased by the spring 226 into a holding engagement with the notch 214 on the rear end of the bar 200. When the transfer means 17 is fully retracted, the abutment screw 237 engages the lever 228 to unlatch or unlock the holding means and permit the retainer plate 194 to move down to its normal operative container retaining position.

The pusher means fluid motor 148 is subjected to a steady pressure when the pusher means 16 is retracted, and to a decreasing pressure under control of the variable pressure regulator 172 when the pusher means 16 is advancing and maintaining a pressure on the containers 60 in the magazine section 14.

The variable pressure regulator 172 constantly decreases the pressure on the pusher means 16 as it advances forwardly to overcome any problem of pushing the containers out of the magazine section 14 before they are removed by the feed means of the forming and filling machine 11. If the air pres sure was held constant on the motor 148 when it was advancing the pusher means 16, a point would be reached in the travel of the pusher means 16 when the number of containers in the magazine section 14 would be reduced to an amount so that the pusher means would push the remaining containers out of the magazine section 14. The provision of the variable pressure regulator 172 provides a container loader apparatus wherein when the magazine section 14 is loaded with containers, all of the containers are fed out to the feeder means of a forming and filling machine in a one-by-one manner until the last container in the magazine has been delivered, without danger of having the last few of the containers in the magazine section 14 being accidentally pushed out. The flow regulators 308, 311, 319 and 322 are conventional speed control devices employed in fluid flow control circuits.

The limit switch 11 L.S. is operatively connected in the main control circuit (not shown) of the forming and filling machine 11. it functions as a safety device, whereby if the magazine section 14 runs out of containers, the limit switch operator 175 on the pusher carriage 133 will engage the limit switch 11 L8. to shut down the entire machine.

In one loading apparatus embodying the invention, the magazine section 14, in its fully loaded condition, held about 425 containers. The reserve section 15 held about 300 containers, and the loading tray magazine 18 held about 300 containers. In the last mentioned loading apparatus, when the stack of containers in the reserve section 15 is reduced to about 125 containers, the 300 containers in the reserve section 15 are fed forward automatically to bring the stack of containers in the magazine 14 up to capacity. When the reserve section 15 is thus emptied, the operator may load an additional 300 containers into the reserve section 15 immediately, and a further 300 containers may be dumped from a container carton into the loading tray without any touching of the containers by human hands. However, if the operator desires, he may wait until all but about 75 of the 425 containers in the magazine section 14 are used up. At such time, he may then load the loading tray and in a short time completely build up the number ofcontainers in the magazine section 14 to full capacity.

While it will be apparent that the preferred embodiment of the invention herein disclosed is well calculated to fulfill the objects above stated,- it will be appreciated that the invention is susceptible to modification, variation and change.

We claim:

1. In a container loading apparatus for feeding containers to a feeder means on a container forming and filling machine, the combination comprising:

a. a container conveyor means including a magazine feed section for operatively supporting a first stack of containers for feeding the containers to said feeder means, and container reserve section for operatively supporting a reserve second stack of containers for automatic transfer to said magazine feed section when the first stack is reduced to a predetermined number of containers;

b. means operatively mounted on said conveyor means for maintaining a pressure on said first stack of containers in said magazine feed section for continuously feeding the containers in said first stack of containers to said feeder means;

. transfer means operatively engageable with said second stack of containers in said reserve section for transferring said second stack of containers from said reserve section to said magazine feed section for replenishing said first stack of containers;

means for loading containers into said conveyor means reserve section for renewing said first stack of containers;

e. said means for loading containers into said conveyor means reserve section includes a loading tray means hingedly mounted on said conveyor means adjacent said reserve section; and

said loading tray means includes:

1. a frame means hingedly mounted on said conveyor means adjacent said conveyor means reserve section;

2. a fixed abutment means disposed at one end of said hinge means; and

. a tray movably mounted on said hinge means for lateral movement toward and away from said fixed abutment means and having a closed end opposite to said fixed abutment means and an open end adjacent said fixed abutment means, whereby a third stack of containers may be disposed in the tray when it is in a first position moved laterally away from said fixed abutment means, and the tray may then be moved on said frame means towards said fixed abutment means to a second position to compress the third stack of containers before it is loaded into said conveyor means reserve section.

2. In a container loading apparatus for feeding containers to a feeder means on a container forming and filling machine, the combination comprising:

a. a container conveyor means including a magazine feed section for operatively supporting a first stack of containers for feeding the containers to said feeder means, and a container reserve section for operatively supporting a reserve second stack of containers for automatic transfer to said magazine feed section when the first stack is reduced to a predetermined number of containers;

b. means operatively mounted on said conveyor means for maintaining a pressure on said first stack of containersin said magazine feed section for continuously feeding the containers in said first stack of containers to said feeder means;

. transfer means operatively engageable with said second stack of containers in said reserve section for transferring said second stack of containers from said reserve section to said magazine feed section for replenishing said first stack of containers; cl. said container conveyor means includes container retainer means for releasably engaging the front container in said first stack of containers in said magazine feed section to retain said front container in said first stack until it is removed by said feeder means; and

e. said means for maintaining a pressure on said first stack of containers includes a pressure means engageable with the last container in said first stack of containers and operative to maintain a decreasing pressure on said first stack of containers so that the pressure decreases as the number of containers in said first stack decreases.

3. A container loader .apparatus as defined in claim 1,

wherein:

a. said fixed abutment means comprises a vertically disposed plate having one end fixed to said conveyor means.

4. A container loader apparatus as defined in claim 1,

wherein:

a. said loading tray means is provided with a safety means to prevent rotation of the loading tray when the tray is in said first position.

5. A container loader apparatus as defined in claim 2, wherein said means for maintaining a decreasing pressure on said first stack of containers includes:

a. a pusher means engageable with the last container in said first stack of containers; and

b. power operated means operatively connected to said pusher means for moving said pusher means against said first stack of containers with a pushing pressure that decreases as the number of containers in said first stack decreases.

6. A container loader apparatus as defined in claim 5,

wherein said power operated means includes:

a. a pressurized fluid operated motor means; and,

b. means operatively interconnecting said fluid motor means to said pusher means.

7. A container loader apparatus as defined in claim 6,

wherein said pressurized fluid operated motor means includes:

a. a pressurized fluid operated rotary motor; and,

b. a pressure regulator means operatively connected to said rotary motor.

8. A container loader apparatus as defined in claim 6, wherein said means operatively interconnecting said fluid motor means to said pusher means includes:

a. a chain and sprocket drive train.

9. A container loader apparatus as defined in claim 5, including:

a. control means operably interconnected with said pusher means, said power operated means and said transfer means, whereby when the number of containers in said first stack is decreased to a predetermined number of containers, the power operated means will retract said pusher means to allow said transfer means to transfer said second stack'of containers into said reserve section, after which the power operated means will advance said pusher means into pushing engagement with the last of the containers which replenished the first stack of containers.

10. A container loader apparatus as defined in claim 9,

wherein said transfer means includes:

a. a carrier means;

b. a pusher member supported by said carrier means and engageable with the last container in said first stack of containers;

c. a retainer means movably mounted on said carrier means and movable between a first position engageable with the front container in said first stack of containers during a transfer operation, and a second position spaced apart from said front container to release the transfer means from said second stack of containers after said second stack of containers has been transferred into said magazine section.

11. A container loader apparatus as defined in claim. 10,

wherein said transfer means further includes:

a. power operated means operatively connected to the carrier means for moving said carrier means between a first position in said reserve section and a second position in said magazine section.

12. A container loader apparatus as defined in claim 11,

wherein said transfer means further includes: I

a. a pressurized fluid operated motor means controlled by said control means; and,

b. means operatively connecting said fluid motor means to said carrier means.

13. A container loader apparatus as defined in claim 12, wherein said means operatively connecting said fluid motor means to said carrier means includes:

a. a chain and sprocket drive train.

14. A container loader apparatus as defined in claim 10, wherein said transfer means further includes:

a. means for moving said retainer means from said first position to said section position;

b. holding means for holding said retainer means in said second position while said carrier means is moved from said second position to said first position; and,

c. means for releasing said holding means when said carrier means is returned to said first position.

15. A container loader apparatus as defined in claim 14,

wherein:

a. said retainer means is pivotally mounted on a horizontal pivot means and movable by gravity to said first position; and,

b. said means for moving said retainer means from said first position to said second position includes:

1. a cam follower carried by said retainer means; and,

2. a cam means disposed in the path of movement of said cam follower, whereby when said carrier means is moved to said second position, said cam follower engages said cam means and said retainer means is pivoted upwardly to said second position.

16. A container loader apparatus as defined in claim 15, wherein:

a. said cam means is fixed on said pusher means which engages the last container in said first stack of containers.

17. A container loader apparatus as defined in claim 15, wherein said holding means includes:

a. a holding member pivotally mounted adjacent said retainer means and biased into holding engagement with said retainer means when said retainer means is moved to its second position, said holding member being operative to hold the retainer means in its second position when said carrier means is returned to its first position, and said holding member being engageable by said releasing means when the carrier means is returned to its first posi-- tion to detach the holding member from the retainer means to allow it to move by gravity downwardly to its first position.

18. A container loader apparatus as defined in claim 17,

wherein:

a. said holding means further includes a lever attached to said pivotally mounted holding member; and,

b. said means for releasing said holding means includes an abutment member mounted on said container conveyor means, for engagement with said lever to rotate the lever when the carrier means is returned to its first position so as to pivot said holding member to a position detached from said retainer means to permit it to move by gravity to its first position.

19. A container loader apparatus as defined in claim 18,

wherein:

a. said abutment member is adjustably mounted on said container conveyor means.

20. In a container loading apparatus for continuously feeding containers to a feeder means on a container forming and filling machine, the combination comprising:

a. an elongated conveyor plate for slidably supporting a first stack of collapsed containers at one end thereof and a second stack of collapsed containers at the other end thereof;

b. a conveyor track operatively mounted adjacent said conveyor plate;

c. a pusher means movably mounted on said conveyor track for maintaining a variable pushing pressure on said first stack of containers for feeding them to the container forming and filling machine;

means and a variable pressure regulator means operatively connected to said power means, for moving the pusher means.

22. A container loading apparatus as defined in claim 20,

wherein:

a. said transfer means is provided with a fluid operated power means for moving the same. 23. A container loading apparatus as defined in claim 20, including:

a. an elongated support bar mounted over said conveyor plate, and said transfer means is slidably mounted on said support bar. 24. A container loading apparatus as defined in claim 20,

wherein:

a. said loading means includes a loading tray hingedly mounted adjacent said other end of said conveyor plate 

